US8336525B2 - Apparatus, system, and method for estimating deterioration of a NOx sensor response rate - Google Patents

Apparatus, system, and method for estimating deterioration of a NOx sensor response rate Download PDF

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US8336525B2
US8336525B2 US12/822,963 US82296310A US8336525B2 US 8336525 B2 US8336525 B2 US 8336525B2 US 82296310 A US82296310 A US 82296310A US 8336525 B2 US8336525 B2 US 8336525B2
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time
sensor
sensor signal
value
estimated
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US20110016849A1 (en
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Jeff Runde
Xiao Lin
Daniel D. Wilhelm
David Everard
Carlos A. Lana
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Cummins Intellectual Property Inc
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/22—Safety or indicating devices for abnormal conditions
    • F02D41/222—Safety or indicating devices for abnormal conditions relating to the failure of sensors or parameter detection devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
    • F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
    • F02D41/146—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being an NOx content or concentration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
    • F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
    • F02D41/146—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being an NOx content or concentration
    • F02D41/1463—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being an NOx content or concentration of the exhaust gases downstream of exhaust gas treatment apparatus
    • F02D41/1465—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being an NOx content or concentration of the exhaust gases downstream of exhaust gas treatment apparatus with determination means using an estimation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2560/00—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
    • F01N2560/02—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor
    • F01N2560/026—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor for measuring or detecting NOx
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/40—Engine management systems

Definitions

  • This invention relates to exhaust systems for internal combustion engines, and more particularly to estimating a response rate deterioration of a NO x sensor configured to detect NO x in an exhaust gas stream.
  • Exhaust after-treatment systems receive and treat exhaust gas generated from an internal combustion engine.
  • Typical exhaust after-treatment systems include any of various components configured to reduce the level of harmful exhaust emissions present in the exhaust gas.
  • some exhaust after-treatment systems for diesel powered internal combustion engines include various components, such as a diesel oxidation catalyst (DOC), particulate matter filter or diesel particulate filter (DPF), and selective catalytic reduction (SCR) catalyst.
  • DOC diesel oxidation catalyst
  • DPF diesel particulate matter filter
  • SCR selective catalytic reduction
  • exhaust gas first passes through the diesel oxidation catalyst, then passes through the diesel particulate filter, and subsequently passes through the SCR catalyst.
  • Each of the DOC, DPF, and SCR catalyst components is configured to perform a particular exhaust emissions treatment operation on the exhaust gas passing through the components.
  • the DOC reduces the amount of carbon monoxide and hydrocarbons present in the exhaust gas via oxidation techniques.
  • the DPF filters harmful diesel particulate matter and soot present in the exhaust gas.
  • the SCR catalyst reduces the amount of nitrogen oxides (NO x ) present in the exhaust gas.
  • the operation of the engine and exhaust after-treatment components are based largely on the amount of NO x present in the exhaust gas stream at various stages within the exhaust after-treatment system.
  • the amount of NO x in the exhaust stream typically is detected using one or more NO x sensors placed at least partially within the exhaust gas stream flowing through the exhaust after-treatment system.
  • some conventional exhaust after-treatment systems include a NO x sensor proximate an outlet of the engine exhaust manifold, an outlet of the SCR catalyst, and an outlet of the tailpipe.
  • Each NO x sensor detects a NO x level in the exhaust gas stream and transmits a signal representing the detected NO x level to an electronic control module (ECM) or intermediate module.
  • ECM electronice control module
  • the ECM processes the detected NO x level received from the NO x sensor according to any of various computational methods to estimate the amount of NO x present in the exhaust gas stream at the particular location of the NO x sensor.
  • the accuracy of the NO x level detected by the NO x sensors is important. Of particular importance is the accuracy of the signal from the tailpipe NO x sensor as it indicates the amount of NO x exiting the exhaust after-treatment system into the atmosphere. If the tailpipe NO x sensor is inaccurately detecting the level of NO x in the exhaust gas stream exiting the system, the system may be unnecessarily reducing too much NO x or unknowingly reducing too little NO x . For example, if the NO x level detected by the tailpipe NO x sensor is erroneously high, then the system could be inefficiently reducing more NO x than is necessary. Alternatively, if the NO x level detected by the tailpipe NO x sensor is erroneously low, then the system may not be reducing enough NO x to meet emissions standards.
  • One source for inaccurate NO x level detection is the deterioration of the NO x sensor response rate over time.
  • the deterioration of the NO x sensor response rate increases and the accuracy of the NO x level detected by the NO x sensor decreases.
  • Some conventional systems are equipped to estimate the level of deterioration of a NO x sensor response rate. These systems may use various techniques and methods for estimating the NO x sensor response rate deterioration level. However, these techniques and methods may suffer from certain drawbacks. For example, some systems do not distinguish between a slow change rate of a NO x sensor signal and a slow response due to NO x sensor deterioration. Additionally, some systems do not account for signal offset drift (e.g., noise) and transfer delays that may be characteristic of particular NO x sensor signals, such as signals from a tailpipe NO x sensor.
  • signal offset drift e.g., noise
  • the subject matter of the present application has been developed in response to the limitations of present state of the art concerning exhaust after-treatment control systems and on-board diagnostic systems. Accordingly, the subject matter of the present application has been developed to provide an apparatus, a system, and a method that overcomes at least some of the shortcomings of the present state of the art.
  • an apparatus for determining a deterioration of a NO x sensor response rate in an internal combustion engine system includes an engine control module configured to stop fueling to an internal combustion engine during motoring of the internal combustion engine.
  • the apparatus also includes a signal monitoring module configured to monitor a NO x sensor signal after the engine control module stops fueling to the internal combustion engine during motoring of the engine and store NO x sensor signal data corresponding to the monitored NO x sensor signal.
  • the apparatus includes a time constant module that is configured to determine a time constant of the NO x sensor response after the engine control module stops fueling.
  • the apparatus further includes a response rate deterioration module configured to determine a response rate deterioration value of the NO x sensor based at least partially on the determined time constant.
  • the time constant of the NO x sensor response is determined using function fitting method, which can be a least squares fit method in certain instances.
  • the curve fit of the least squares fit method can be defined by the values k and k 2 that provide the smallest value of ⁇ according to the equation
  • the time constant of the NO x sensor signal response is based on a discrete-time approximation of a continuous mathematical function.
  • the response rate deterioration module is configured to determine an offset drift of the NO x sensor signal.
  • the time constant can be based at least partially on the offset drift.
  • the response rate deterioration module is configured to determine a transfer delay of the NO x sensor signal.
  • the transfer delay of the NO x sensor signal can be based at least partially on an estimated starting time of a decay of the NO x sensor signal response.
  • the estimated starting time of the decay of the NO x sensor signal response is based on a comparison between an estimated NO x value at a time after the engine control module stops fueling and a sensed NO x value at the same time.
  • the estimated starting time of the decay of the NO x sensor signal is equal to the time at which a difference between the estimated NO x value and the sensed NO x value is above a threshold.
  • the estimated NO x value can be estimated using a curve fit of the stored NO x sensor signal data during a testing time window after the engine control module stops fueling to the internal combustion engine during motoring of the internal combustion engine. In such implementations, the estimated NO x value can be estimated at a time prior to a start of the testing time window.
  • a system for determining a sensor condition includes a sensor that is configured to detect a property value and generate a response signal representative of the detected property value.
  • the system also includes a controller communicable in response signal receiving communication with the sensor.
  • the controller is configured to monitor the decay rate of a response signal received from the sensor and determine a deterioration factor corresponding with the response signal.
  • the controller models the sensor response as a first order linear dynamical system where the decay rate is the negative inverse of the system time constant.
  • the controller can be configured to determine the decay rate by estimating the system time constant from the sensor signal using, for example, a least squares fit method.
  • the deterioration factor can be based at least partially on the estimated system time constant.
  • the system further includes an internal combustion engine capable of generating an exhaust gas stream.
  • the sensor is configured to detect a property value of the exhaust gas stream.
  • the internal combustion engine is in fueling receiving communication with a fuel source.
  • the time constant can be a time constant of the response signal during a prescheduled testing period.
  • the prescheduled testing period can be defined as a time period during which fueling of the internal combustion engine is stopped while motoring of the internal combustion engine is maintained.
  • the system also includes an on-board diagnostics indicator communicable in signal receiving communication with the controller.
  • the controller signals the on-board diagnostics indicator to indicate a condition of the sensor in response to an estimated deterioration factor being above a threshold.
  • the system may also include an internal combustion engine and a NO x sensor configured to detect an amount of NO x in an exhaust gas stream generated by the engine.
  • the controller can be configured to stop fueling of the engine and monitor a decay rate of the response signal while fueling of the engine is stopped.
  • a method for determining a deterioration of a NO x sensor response rate includes stopping fuel consumption in an internal combustion engine during motoring of the engine and monitoring a NO x sensor signal after fuel consumption has been stopped.
  • the method also includes estimating a decay rate of the NO x sensor signal using a function fitting method, such as least squares fit.
  • a function fitting method can be used interchangeably with a curve fitting method.
  • the method includes estimating a deterioration value of a response rate of the NO x sensor signal based at least partially on the estimated decay rate.
  • the method includes estimating a transfer delay of the NO x sensor signal by estimating a starting time of a decay of the NO x sensor signal after fuel consumption has been stopped based on stored NO x sensor signal data collected during a predetermined time period following fuel consumption stoppage.
  • the decay rate of the NO x sensor signal can be estimated based on the estimated starting time of the decay of the NO x sensor signal.
  • a length of the predetermined time period can be based on at least one of a length of an exhaust after-treatment system to which the NO x sensor signal is coupled, a flow rate of exhaust gas through the exhaust after-treatment system, a diameter of an exhaust pipe of the exhaust after-treatment system, and a response time of the NO x sensor in a non-deteriorated condition.
  • Estimating the starting time of the NO x sensor signal decay can include using a first set of data of the stored NO x sensor signal data associated with a first time window to curve fit a first exponential function or non-exponential function having characteristics similar to an exponential function.
  • the method can additionally include using the curve fit of the first exponential function to estimate a NO x value at a first time before the first time window and comparing the estimated NO x value at the first time with an actual NO x value at the first time. If the difference between the estimated NO x value and the actual NO x value is above a threshold, the method includes setting the first time as the starting time of the NO x sensor signal decay.
  • the method includes using a second set of data of the stored NO x sensor signal data associated with a second time window starting before the first time window to curve fit a second exponential function. Also, if the above conditions are met, the method includes using the curve fit of the second exponential function to estimate a NO x value at a second time before the second time window and the first time, comparing the estimated NO x value at the second time with an actual NO x value at the second time, and setting the second time as the starting time of the NO x sensor signal decay if the difference between the estimated NO x value at the second time and the actual NO x value at the second time is above the threshold.
  • the decay rate of the NO x sensor signal is estimated based on the estimated starting time of the decay of the NO x sensor signal.
  • a length of the predetermined time period can be based on at least one of a length of an exhaust after-treatment system to which the NO x sensor signal is coupled, a flow rate of exhaust gas through the exhaust after-treatment system, a diameter of an exhaust pipe of the exhaust after-treatment system, and a response time of the NO x sensor in a non-deteriorated condition.
  • estimating the starting time of the decay of the NO x sensor signal includes analyzing stored NO x sensor signal data after a predicted starting time of the NO x sensor signal decay and incrementally backtracking to analyze earlier stored NO x sensor signal data.
  • FIG. 1 is a schematic block diagram of an internal combustion engine system having an exhaust after-treatment system and a controller according to one representative embodiment
  • FIG. 2 is a schematic block diagram of a controller of an internal combustion engine system according to one representative embodiment
  • FIG. 3 is a graph of actual and sensed values for NO x and fueling as a function of time according to one representative embodiment
  • FIG. 4 is a graph of sensed NO x values for a signal response and an estimated curve fit of the sensed NO x values according to one representative embodiment
  • FIG. 5 is a schematic block diagram of a time constant module according to one representative embodiment.
  • FIG. 6 is a flow chart of a method for determining a start time of a sensor signal decay response according to one representative embodiment.
  • the NO x sensor response rate deterioration is estimated based on a NO x sensor response during a vehicle motoring condition using a function fitting method, such as, but not limited to, least squares.
  • the NO x sensor response rate deterioration estimate takes into account possible offset drift and transfer delays that may be associated with the NO x sensor signal response.
  • the method for estimating the deterioration of a NO x sensor response rate discerns between a slow change rate of NO x signal, which can be indicative of a healthy and properly functioning NO x sensor, and a slow response rate due to sensor response rate deterioration, which can be indicative of an old or malfunctioning NO x sensor.
  • the method utilizes a zero-fueling condition of an associated internal combustion engine in determining the NO x sensor response rate deterioration estimate.
  • FIG. 1 depicts one embodiment of an internal combustion engine system 10 .
  • the main components of the engine system 10 include an internal combustion engine 100 , an exhaust gas after-treatment system 200 coupled to the exhaust output of the engine, and a controller 300 .
  • the internal combustion engine 100 can be a compression ignited internal combustion engine, such as a diesel fueled engine, or a spark-ignited internal combustion engine, such as a gasoline fueled engine operated lean.
  • the engine 100 includes an engine block 111 , an air handling system 150 having an air inlet 112 , intake manifold 114 , EGR system 130 , and a fuel delivery system 140 including fuel injectors 115 in fluid receiving communication with a fuel supply 142 .
  • the engine system 10 also includes an exhaust manifold 116 , turbocharger turbine 118 , turbocharger compressor 120 , and various sensors.
  • the engine 100 includes temperature sensors (e.g., temperature sensor 124 ), pressure sensors (e.g., pressure sensor 126 ), an air-flow sensor 156 , NO x sensors (e.g., engine out NO x sensor 172 ), and mass flow sensors (e.g., exhaust mass flow sensor 174 ).
  • the air inlet 112 is vented to the atmosphere and connected to an inlet of the intake manifold 114 to enable air to enter the intake manifold.
  • the intake manifold 114 includes an outlet operatively coupled to the compression chambers 113 of the engine block 111 for introducing intake charge, e.g., air, and EGR gas into the compression chambers.
  • the air handling system 150 may also include a compressor bypass valve 152 that is selectively actuatable to either allow intake air from the air inlet 112 , and EGR gas if the valve 132 is opened, to pass through the compressor 120 or bypass the compressor.
  • the fuel delivery system 140 introduces fuel into the cylinders to intermix with the intake charge and EGR prior to a combustion event in the cylinder.
  • the air from the atmosphere, and EGR gas if desired, is combined with fuel injected via the injectors 115 to power the engine.
  • the injectors 115 are in electrical communication with the controller 300 , which is operable to control the amount of fuel injected into the combustion chamber for combustion. Combustion of the fuel and air produces exhaust gas that is operatively vented to the exhaust manifold 116 . From the exhaust manifold 116 , a portion of the exhaust gas may be used to power the turbocharger turbine 118 .
  • the turbine 118 drives the turbocharger compressor 120 , which may compress at least some of the air entering the air inlet 112 before directing it to the intake manifold 114 and into the compression chambers 113 of the engine block 111 .
  • the engine 100 also includes a turbine 118 bypass valve 119 selectively opened to allow exhaust gas to power the turbine 118 and selectively closed to bypass the exhaust around the turbine 118 and into an exhaust pipe 160 downstream of the turbine.
  • the exhaust gas after-treatment system 200 is coupled to the outlet pipe 160 of the exhaust manifold 116 . At least a portion of the exhaust gas exiting the exhaust manifold 116 can pass through the exhaust after-treatment system 200 .
  • the engine 100 includes the EGR system 130 having an EGR valve 132 configured to open to allow a portion of the exhaust gas to recirculate back into the compression chambers 113 for altering the combustion properties of the engine 100 .
  • the exhaust gas after-treatment system 200 is configured to remove various chemical compound and particulate emissions present in the exhaust gas received from the exhaust manifold 116 and not recirculated back into the cylinders 113 of the engine block 111 .
  • the exhaust gas after-treatment system 200 includes an oxidation catalyst 210 , a particulate matter (PM) filter 220 , an SCR system 230 having a reductant delivery system 232 and an SCR catalyst 234 , and an ammonia oxidation (AMOX) catalyst 240 .
  • exhaust may flow from the exhaust manifold pipe 160 , through the oxidation catalyst 210 , through the particulate filter 220 , through the SCR catalyst 234 , through the AMOX catalyst 240 , and then be expelled into the atmosphere via a tailpipe.
  • the particulate filter 220 is positioned downstream of the oxidation catalyst 210
  • the SCR catalyst 234 is positioned downstream of the particulate filter 220
  • the AMOX catalyst 240 is positioned downstream of the SCR catalyst 234 .
  • exhaust gas treated in the exhaust gas after-treatment system 200 and released into the atmosphere consequently contains significantly fewer pollutants, such as diesel particulate matter, NO x , hydrocarbons, such as carbon monoxide and carbon dioxide, than untreated exhaust gas.
  • the oxidation catalyst 210 can be any of various flow-through, diesel oxidation catalysts (DOC) known in the art.
  • DOC diesel oxidation catalysts
  • the oxidation catalyst 210 is configured to oxidize at least some particulate matter, e.g., the soluble organic fraction of soot, in the exhaust and reduce unburned hydrocarbons and CO in the exhaust to less environmentally harmful compounds.
  • the oxidation catalyst 210 may sufficiently reduce the hydrocarbon and CO concentrations in the exhaust to meet the requisite emissions standards.
  • the particulate filter 220 can be any of various particulate filters known in the art configured to reduce particulate matter concentrations, e.g., soot and ash, in the exhaust gas to meet requisite emission standards.
  • the particulate filter 220 can be electrically coupled to a controller, such as controller 300 , that controls various characteristics of the particulate filter, such as, for example, the timing and duration of filter regeneration events.
  • the particulate filter 220 and associated control system is similar to, or the same as, the respective particulate filters and control systems described in U.S. patent application Ser. Nos. 11/227,320; 11/227,403; 11/227,857; and 11/301,998 (hereinafter “incorporated particulate filter applications”), which are incorporated herein by reference.
  • the SCR system 230 can be similar to the SCR system described in U.S. patent application Ser. No. 12/112,500, filed Apr. 30, 2008, U.S. patent application Ser. No. 12/112,622, filed Apr. 30, 2008, U.S. patent application Ser. No. 12/112,678, filed Apr. 30, 2008, and U.S. patent application Ser. No. 12/112,795, filed Apr. 30, 2008 (hereinafter “incorporated SCR patent applications”), which are each incorporated herein by reference.
  • the SCR system 230 includes a reductant delivery system 232 that includes a reductant source, pump and delivery mechanism or injector, which are not shown.
  • the reductant source can be a container or tank capable of retaining a reductant, such as, for example, ammonia (NH 3 ), urea, diesel fuel, or diesel oil.
  • the reductant source is in reductant supplying communication with the pump, which is configured to pump reductant from the reductant source to the delivery mechanism.
  • the delivery mechanism can include a reductant injector positioned upstream of the SCR catalyst 234 . The injector is selectively controllable to inject reductant directly into the exhaust gas stream prior to entering the SCR catalyst 234 .
  • the reductant can either be ammonia or urea, which decomposes to produce ammonia.
  • the ammonia reacts with NO x in the presence of the SCR catalyst 234 to reduce the NO x to less harmful emissions, such as N 2 and H 2 O.
  • the SCR catalyst 234 can be any of various catalysts known in the art.
  • the SCR catalyst 234 is a vanadium-based catalyst, and in other implementations, the SCR catalyst is a zeolite-based catalyst, such as a Cu-Zeolite or a Fe-Zeolite catalyst.
  • the reductant is aqueous urea and the SCR catalyst 234 is a zeolite-based catalyst.
  • the AMOX catalyst 240 can be any of various flow-through catalysts configured to react with ammonia to produce mainly nitrogen. Generally, the AMOX catalyst 240 is utilized to remove ammonia that has slipped through or exited the SCR catalyst 234 without reacting with NO x in the exhaust. In certain instances, the after-treatment system 200 can be operable with or without an AMOX catalyst. Further, although the AMOX catalyst 240 is shown as a separate unit from the SCR catalyst 234 , in some implementations, the AMOX catalyst can be integrated with the SCR catalyst, e.g., the AMOX catalyst and the SCR catalyst can be located within the same housing.
  • the exhaust after-treatment system 200 includes various sensors, such as temperature sensors (e.g., temperature sensors 224 , 224 A, 224 B), pressure sensor (e.g. pressure sensor 226 ), oxygen sensors (e.g., oxygen sensor 270 ), NO x sensors (e.g., SCR catalyst NO x sensor 272 A, SCR catalyst outlet NO x sensor 272 B, and tailpipe NOx sensor 272 C), NH 3 sensors (e.g., NH 3 sensor 274 ), dual ammonia/NO x sensors (not shown) and the like, that are disposed throughout the exhaust gas after-treatment system.
  • temperature sensors e.g., temperature sensors 224 , 224 A, 224 B
  • pressure sensor e.g. pressure sensor 226
  • oxygen sensors e.g., oxygen sensor 270
  • NO x sensors e.g., SCR catalyst NO x sensor 272 A, SCR catalyst outlet NO x sensor 272 B, and tailpipe NOx sensor 272 C
  • NH 3 sensors
  • the various sensors of the engine 100 and exhaust after-treatment system 200 may be in electrical communication with the controller 300 .
  • the controller 300 is operable to monitor operating conditions and control the engine 100 and exhaust after-treatment system 200 .
  • the engine system 10 includes a signal relay 20 in signal receiving communication with one or more of the sensors of the system 10 . Although the signal relay 20 in FIG.
  • the signal relay 20 can be in electrical communication with fewer or more illustrated or non-illustrated sensors of the engine system 10 .
  • the signal relay 20 may transmit the received signals to the controller for computation and analysis.
  • the engine system 10 does not include a signal relay 20 , and each of the various sensors of the engine system is in electrical communication directly with the controller 300 .
  • the sensors of the engine system 10 are configured to detect a property value and generate a response signal representative of the detected property value.
  • the sensors of the engine system 10 can be configured to detect respective property values associated with exhaust gas flowing from the engine 100 through the exhaust after-treatment system 200 .
  • the sensors can be designed to detect or sample a respective property value periodically, e.g., once every 200 milliseconds. For each detection period, a sensor transmits a response representative of the detected property value to the controller 300 via a signal relay 20 if desired.
  • the controller interprets the response received from the sensor using predetermined look-up tables or algorithms to determine a numerical amount of the detected property.
  • the response rate of the sensors following detection of a property value is relatively quick, e.g., above a certain threshold.
  • the response rate of the sensors may be relatively slow, e.g., below a threshold.
  • the response rate is slow, the accuracy of the sensor is compromised and the system performance and emissions compliance may be hampered as a result. Accordingly, regulations are in place requiring on-board diagnostic controls that notify a user of a sensor having a response rate deterioration level above a certain threshold.
  • the controller 300 is configured to estimate the deterioration level of the response rate of the various sensors. The controller 300 then notifies an on-board diagnostics system to alert a user if an estimated deterioration level is above a threshold by communicating with the on-board diagnostic interface 900 .
  • the controller 300 in FIG. 1 is depicted as a single physical unit, but can include two or more physically separated units or components in some embodiments if desired.
  • the controller 300 receives multiple inputs, processes the inputs, and transmits multiple outputs.
  • the multiple inputs may include sensed measurements from the sensors, virtual sensor inputs, and various user inputs.
  • the inputs are processed by the controller 300 using various algorithms, stored data, and other inputs to update the stored data and/or generate output values.
  • the generated output values and/or commands are transmitted to other components of the controller and/or to one or more elements of the engine system 10 to control the system to achieve desired results, and more specifically, to achieve desired exhaust gas emissions at the tailpipe.
  • the description of the response rate deterioration estimation features of the controller 300 will proceed with reference to the tailpipe NO x sensor 272 C.
  • the following principles associated with response rate deterioration is applicable to other sensors configured to detect other property values without departing from the essence of the invention.
  • the controller 300 includes an engine control module 310 configured to operate the engine 100 in a vehicle motoring condition by generating a stop fueling command 315 .
  • the stop fueling command 315 is transmitted directly to the fuel injectors 115 or a fuel injection control module (not shown).
  • the fuel injectors 115 stop the supply of fuel to the combustion chambers.
  • the fuel supply to the engine 100 which is represented by line 410 , is stopped at time T start .
  • combustion is not taking place and combustion byproducts in the exhaust exiting the engine 100 are reduced to a constant value at approximately the same time that fueling stops or the vehicle motoring condition starts, i.e., at time T start .
  • the value is reduced to approximately zero.
  • the actual amount of NO x in the exhaust exiting the engine is represented by line 420 .
  • the transfer delay represents the amount of time for the last amount of NO x generated by the engine 100 before the vehicle motoring condition is initiated to pass through post-engine systems, pass through the exhaust after-treatment system, and pass by the tailpipe NO x sensor 272 C.
  • the transfer delay of an engine system 10 is dependent upon many factors and is typically different for different vehicle platforms. Typical factors include the size of after-treatment system components, the length of the after-treatment system, the number of after-treatment system components, etc. Based on the engine system configuration, in some embodiments, the transfer delay can vary from about tens of milliseconds to about six seconds.
  • the engine control module 310 can be configured to operate the engine 100 in a vehicle motoring condition according to a tailpipe NO x sensor testing schedule.
  • the tailpipe NO x sensor testing schedule can include a plurality of testing periods occurring at a predetermined rate, for example, once every day, week, month, or other desirable periodic rate.
  • the testing periods of the NO x sensor testing schedule can be adjustable over time based on any of various engine operating conditions, user input, and external factors.
  • the testing periods each represent a period of time in which the controller 300 receives and stores sensor signal data. Following a testing period, the controller 300 estimates a current deterioration value of the tailpipe NO x sensor 272 C and forwards an OBD alert command 355 to the OBD interface 900 if necessary.
  • the testing period is represented in graph 400 as the time between time T start and time T end .
  • a signal monitoring module 320 of the controller 300 monitors sensor signals 305 received from the tailpipe NO x sensor 272 C.
  • a representative monitored sensor signal 305 from a tailpipe NO x sensor 272 C is represented by line 440 of graph 400 (see FIG. 3 ).
  • the signal monitoring module 320 stores in a memory a plurality of NO x sensor data points. Each data point includes a NO x value indicated by a sensor signal 305 and an associated time value, which can be representative of the time at which the signal was received by the signal monitoring module.
  • the signal monitoring module 320 continuously collects and stores data points while the engine is operating in the vehicle motoring condition, e.g., during the NO x sensor testing periods or between time T start and time T end (see FIG. 3 ).
  • the detected amount of NO x 440 in the exhaust gas stream at the tailpipe does not drop to zero or near zero at time T decay along with the actual amount of NO x 430 in the exhaust gas stream. Rather, at time T decay , the detected amount of NO x 440 begins to decay by following an exponential-like function even when the tailpipe NO x sensor signal is a step function. Accordingly, the decay rate of the detected amount of NO x 440 can be quantified by modeling the exponential-like function with an exponential function and defining the decay rate of the exponential-like function as the decay rate of the exponential function. For convenience in formulating the parameter estimation problem as will be described below, the exponential function can be represented as the solution of a first order non-homogeneous linear differential equation.
  • the time constant module 330 of the controller 300 is configured to estimate a time constant of the detected amount of NO x using a curve fit method.
  • the signal decay curve fit 460 of the detected amount of NO x 440 is represented in graph 450 of FIG. 4 .
  • the curve fit 460 of FIG. 4 can be represented by the following equation:
  • NOx A ⁇ e ( - ( t - t 0 ) ⁇ ) + NOx 0 ( 1 )
  • A is the initial amplitude of the signal prior to decay without sensor drift
  • ⁇ is a time constant representing the rate of decay or deterioration of the signal
  • NOx 0 is the NO x offset drift 360 (see FIGS. 3 and 4 ).
  • NO x offset drift is the difference between a sensed output signal of a property at equilibrium or steady state and the actual property value at equilibrium or steady state.
  • NOx offset drift NOx 0 represents noise present in the system or modeling uncertainty.
  • NO x offset drift NOx 0 has some value different from zero because in practice the NO x value does not decay exponentially and at least some noise is present.
  • the time constant ⁇ represents the time constant for a continuous mathematical function similar to Equation 1. In other terms, the time constant ⁇ represents how quickly the NO x signal approaches equilibrium and is equal to the inverse of the exponential decay rate with negative sign. The time constant ⁇ can be used to assess the NO x sensor response rate deterioration.
  • the time constant module 330 is configured to first determine a constant k of a discrete-time approximation of the continuous mathematical function (e.g., Equation 1) as will be described below.
  • the time constant module 330 estimates the parameters that define the exponential decay curve 460 by fitting the decay curve to the signal curve 440 .
  • Equation 1 can be written as the solution of a first order non-homogeneous linear differential equation.
  • a more convenient form for parameter estimation is to approximate the first order non-homogeneous linear differential equation with a non-homogeneous linear difference equation. Any of the available approximation methods can be used in this embodiment.
  • the least squares curve fit 460 is defined by the values of k and k 2 that provide the smallest value of ⁇ in Equation 3 as follows:
  • Equation 3 The values of k and k 2 that minimize ⁇ in Equation 3 can be obtained by taking the partial derivatives of the summation ⁇ with respect to k and k 2 and setting them to zero as follows:
  • Equation 4 can be rearranged to read:
  • Equation 5 can be rearranged to read:
  • c 1 k 2 a 1 +kb 1 (14)
  • c 2 k 2 a 2 +kb 2 (15)
  • k a 2 ⁇ c 1 - a 1 ⁇ c 2 a 2 ⁇ b 1 - a 1 ⁇ b 2 ( 16 )
  • k 2 b 1 ⁇ c 2 - b 2 ⁇ c 1 a 2 ⁇ b 1 - a 1 ⁇ b 2 ( 17 )
  • u k 2 k ( 18 )
  • the parameter u is equal to the NO x offset drift NOx 0 of Equation 1.
  • the time constant module 330 is configured to determine the time constant 335 (i.e., time constant ⁇ ) of the tailpipe NO x sensor signal during a vehicle motoring condition, as well as determine the NO x offset drift NOx 0 of the tailpipe NO x sensor signal, i.e. NO x offset drift 360 (see FIG. 2 ).
  • the expressions to estimate k and k 2 may be different than those shown in Equations 16 and 17, respectively.
  • the expressions to estimate k and k 2 can be obtained by following a derivation process similar to the one represented by Equations 4-19 above but using a different definition of ⁇ associated with the fitting method.
  • the response rate deterioration module 340 is configured to determine a response rate deterioration value 345 or factor.
  • the response rate deterioration value 345 can be any of various values representing a level of deterioration of the tailpipe NO x sensor response rate.
  • the response rate deterioration value 345 can be a one-to-one equivalent of the estimated time constant ⁇ or other equivalent value, such as a scaled percentage or ratio.
  • the determined response rate deterioration value 345 is then compared to a predetermined threshold value by the OBD module 350 . Based on the comparison between the response rate deterioration value 345 and the threshold value, the OBD module 350 may issue an alert command 355 .
  • the threshold value represents a maximum deterioration of the tailpipe NO x sensor response rate allowed by emissions regulations
  • the OBD module 350 will issue an alert command 355 if the response rate deterioration value 345 exceeds the threshold value.
  • the OBD interface 900 commands an OBD indicator to alert a user that the response rate deterioration value is above a threshold. In some instances, the alert will indicate to a user that the sensor has passed or failed, e.g., needs to be replaced or is malfunctioning.
  • the time constant module 330 is also configured to determine the transfer delay 365 , which is equal to the time period between time T start and time T decay as discussed above. Generally, the transfer delay 365 is determined by estimating the time T decay when the signal decay or first order response begins. Additionally, an accurate estimation of the time when the signal decay begins, i.e. T decay , may be important in estimating an accurate time constant.
  • the time constant module 330 includes a transfer delay module 380 , which includes a testing window module 400 , curve fit module 410 , comparison module 420 , and transfer delay calculation module 430 .
  • the transfer delay module 380 utilizes a method 600 for determining the transfer delay 365 (see FIG. 6 ).
  • the method 600 includes analyzing data occurring well after the first order response begins (e.g., right of time T decay in the graph 400 ) and incrementally backtracking to analyze earlier data. The earlier data is compared to the later data until the point at which the response begins to decay (e.g., time T decay ) is found.
  • the testing window module 400 selects a testing time window within which data points may be used for determining the beginning of an estimated first order response.
  • the testing time window extends from time T start to a variable time T w .
  • the time T w depends on one or more factors as desired. For example, in systems having sensors with relatively longer response times or relatively longer exhaust after-treatment systems, the time T w is well after the time T start , e.g., 20 seconds after time T start . However, in systems having sensors with relatively shorter response times or relatively shorter exhaust after-treatment systems, the time T w may be relatively closer to time T start , e.g., 5 seconds after T start . Additionally, the flow rate of exhaust through the after-treatment system and the diameter of the exhaust pipe may affect the selection of time T w .
  • the curve fit module 410 uses a select number of data points within the testing time window between time T w and a variable time T n (see FIG. 3 ) within the testing time window to determine a preliminary or first time constant similar to time constant 335 and a preliminary or first NO x offset drift similar to NO x offset drift 360 .
  • the curve fit module 410 uses the preliminary time constant and NO x offset drift to estimate at 620 of the method 600 the parameters of a preliminary or first curve of the decaying signal response 440 using the equations and techniques discussed above.
  • the selected data points are fewer than all the data points stored by the signal monitoring module 320 between time T w and time T n .
  • the signal monitoring module 320 stores data points at a high rate, e.g, every 200 milliseconds.
  • the data points selected by the curve fit module 410 may be a lower number of data points occurring only every 1,000 milliseconds or more.
  • the selected data points are used to determine a preliminary or first time constant and a preliminary or first NO x offset drift, which are used to estimate a preliminary or first curve fit between time T w and time T n .
  • the curve fit module 410 uses the parameters of the preliminary or first curve estimation between time T w and time T n to estimate the NO x value at the time T n ⁇ 1 at 630 of the method 600 .
  • the comparison module 420 compares the estimated NO x value at time T n ⁇ 1 to the actual NO x value at time T n ⁇ 1 . If the difference between the estimated NO x value at time T n ⁇ 1 and the actual NO x value at time T n ⁇ 1 is below a threshold value at 650 of the method 600 , then n is set to n ⁇ 1 at 660 such that time T n , becomes time T n ⁇ 1 and time T n ⁇ 1 becomes T n ⁇ 2 .
  • the curve fit module 410 then estimates new parameters of a new curve using one or more additional data points occurring earlier in time than the earliest data point used in the first or previous curve fit estimation, e.g., between time T w and time T n ⁇ 1 , and the comparison module 420 performs another NO x value comparison as discussed above. For example, the curve fit module 410 uses the new parameters of the new curve between time T w and time T n ⁇ 1 at 630 to estimate the NO x value at the time T n ⁇ 2 . Then, at 640 , the comparison module 420 compares the estimated NO x value at T n ⁇ 2 to the actual NO x value at T n ⁇ 2 and the method proceeds to 650 .
  • the process of adding earlier data points, estimating additional parameters for additional curves, and comparing estimated NO x values to actual NO x values continues until the difference between the earliest estimated NO x value using the estimated parameters of the latest curve estimation and the corresponding actual NO x value is above a threshold at 650 . Then, the method 600 proceeds to set at 670 the time associated with the beginning of the exponential-like decay of the detected amount of NO x 440 (i.e., time T decay ) to an estimated time T decay,estimate representing the beginning of as the signal decay curve fit 460 shown in FIG. 4 .
  • the estimated time T decay,estimate corresponds with the time associated with the earliest estimated NO x value (as determined at 630 ).
  • the transfer delay module 430 receives the set time T decay and estimates the transfer delay 365 of the system by taking the difference of the time T decay and the T start .
  • the time constant module 330 utilizes the time T decay estimated by the transfer delay module 380 as the beginning of the estimated response signal curve and all the data points between the time T decay and T end in the equations discussed above to estimate a final time constant 335 , final NO x offset drift 360 , and final parameters of the curve fit 460 of the system response.
  • the final estimations are then used by the response rate deterioration module 340 to determine a final response rate deterioration value 345 using the techniques discussed above.
  • the OBD module 350 then issues an alert command 355 as necessary in response to the final response rate deterioration value 345 .
  • modules may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components.
  • a module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
  • Modules may also be implemented in software for execution by various types of processors.
  • An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.
  • a module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
  • operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.
  • the software portions are stored on one or more computer readable media.
  • Reference to a computer readable medium may take any form capable of storing machine-readable instructions on a digital processing apparatus.
  • a computer readable medium may be embodied by a transmission line, a compact disk, digital-video disk, a magnetic tape, a Bernoulli drive, a magnetic disk, a punch card, flash memory, integrated circuits, or other digital processing apparatus memory device.

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  • Combustion & Propulsion (AREA)
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  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Combined Controls Of Internal Combustion Engines (AREA)
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